CHAPTER 8 FLIGHT CONTROLS

Transcription

1 Section Title CHAPTER 8 FLIGHT CONTROLS Flight Controls Introduction Description Cyclic Controls Cyclic Assembly Removal of Cyclic Assembly Installation of Cyclic Assembly Cyclic Grip Assembly Removal of Cyclic Grip Assembly Installation of Cyclic Grip Assembly Cyclic Lateral (Right) Trim Right Trim Spring Assembly Removal Right Trim Spring Assembly Installation Right Trim Spring Replacement and Shimming Cyclic Longitudinal (Fore-Aft) Elastic Trim Cord Longitudinal Trim Cord Removal Longitudinal Trim Cord Installation Cyclic Friction Assembly Cyclic Friction Adjustment A121-7 Push-Pull Tube A121-7 Push-Pull Tube Removal A121-7 Push-Pull Tube Inspection/Repair A121-7 Push-Pull Tube Sleeve Installation A121-7 Push-Pull Tube Sleeve Inspection A121-7 Push-Pull Tube Installation Collective Control Collective Stick Assembly Collective Stick Removal Collective Stick Installation Collective Spring Assembly Collective Spring Removal Collective Spring Installation Collective Spring Adjustment for A038-1 thru -4 Assembly Collective Spring Adjustment for A038-5 and -6 Assembly Page OCT 2014 Chapter 8 Flight Controls Page 8.i

2 Section Title CHAPTER 8 FLIGHT CONTROLS (Continued) Collective Friction Adjustment RPM Governor System A Governor Controller Removal A Governor Controller Installation A Governor Assembly Removal A Governor Assembly Installation C Governor Troubleshooting C Jackshaft and Support Struts Jackshaft Jackshaft Removal Jackshaft Installation Strut Assembly (Jackshaft Support) Strut Removal Strut Installation Swashplate and Main Rotor Pitch Links Swashplate Swashplate Removal Swashplate Installation (Reserved) (Reserved) (Reserved) Shimming Upper (Unflanged) Spherical Sleeve with Aluminum Ball Tail Rotor Controls Tail Rotor Pedals Tail Rotor Pedal Removal Tail Rotor Pedal Installation A317-1 Lower Bellcrank A317-1 Lower Forward Bellcrank Removal A317-1 Lower Forward Bellcrank Installation A316-1 Upper Bellcrank Bellcrank Removal Bellcrank Installation A331-4 Intermediate Bellcrank Bellcrank Removal Page Page 8.ii Chapter 8 Flight Controls OCT 2014

3 Section Title CHAPTER 8 FLIGHT CONTROLS (Continued) Bellcrank Installation A120-3 Aft Bellcrank Bellcrank Removal Bellcrank Installation A031-1 Pitch Control Pitch Control Removal Pitch Control Installation Tail Rotor Pitch Links Tail Rotor Pitch Link Removal Tail Rotor Pitch Link Installation A203 Yoke and A205 Fork Assemblies Bearing Removal C648-2 Bearing Installation A139-1 Bearing Installation B115-1 Bearing Installation Yoke and Fork Assembly Installation Page OCT 2014 Chapter 8 Flight Controls Page 8.iii

4 Intentionally Blank Page 8.iv Chapter 8 Flight Controls OCT 2014

5 CHAPTER 8 FLIGHT CONTROLS Flight Controls Introduction This section covers removal and installation procedures for cyclic controls, collective controls, tail rotor controls and their related components. WARNING Assembly of flight controls is critical and requires inspection by a qualified person. If a second person is not available, the installer must take a 5-minute break prior to inspecting flight control connections he has assembled Description (See Figures 8-1 and 8-2) Dual controls are standard equipment and all primary controls are actuated through pushpull tubes and bellcranks. Bearings used throughout the control system are either sealed ball bearings or have self-lubricated Teflon liners. Flight controls are conventional. The cyclic stick appears to be different but the grip moves the same as in other helicopters due to the free hinge at the center pivot. The cyclic grip is free to move vertically, allowing the pilot to rest his forearm on his knee if he chooses. The collective stick is also conventional with a twist grip throttle control. When the collective is raised, the throttle is opened by an interconnecting linkage. An electronic governor makes minor throttle adjustments required to maintain RPM Cyclic Controls Cyclic Assembly Removal of Cyclic Assembly a. Remove left seat back, center horizontal and vertical panels. b. Remove collective assembly per c. Remove screws holding mixture and carburetor heat control cable covers to cyclic box cover. d. Remove roll pin from cyclic friction knob and remove knob. e. Unscrew right trim knob from trim shaft. f. Remove screws holding cyclic box cover to cyclic box and to side panels. g. Lift cyclic box cover and disconnect post light wire. OCT 2014 Chapter 8 Flight Controls Page 8.1

6 FIGURE 8-1 MAIN ROTOR FLIGHT CONTROLS Page 8.2 Chapter 8 Flight Controls OCT 2014

7 RCBINSCN MAINTENANCE MANUAL MOOELR22 / "' ~-- A330-2 A PEDAL ASSY ill A330-l PEDAL ASSY. &_ j.\ ~ "..._ : Al20-1 r---_11 ~~~~~~-:~K ~= Al24-l I PITCH CONT HOUSING AlOl-4 ROD END Al02-4 ROO END Al25-l PITCH CHANGE STUD o---~~ / / A316-! T. R. BELLCRANK ASSY. Al21-13 P/P TUBE ASSY. Al21-9 P/P TUBE ASSY. ) ~ A317-l BELLCRANK Al21-ll P/P TUBE ASSY. ~ A755-2 & -4 FOR REMOVABLE CONTROLS ~ A755-l & -3 FOR REMOVABLE CONTROLS Issued 5/22/87 FIGURE 8-2 TAIL ROTOR FLIGHT CONTROL Page 8.3

8 MOOEL R Removal of Cyclic Assembly (cont'd) h) Remove screws holding cyclic box assembly to the keel panels. i) j) k) 1) m) n) Unscrew from nutplate but DO NOT remove the two cyclic friction attach bolts or friction spacers may fall out. IF FIREWALL PLUG INSTALLED FOLLO\.J STEPS i AND j Move cyclic stick full fwd. and disconnect bolt holding the Al27-3 rod end to the aft fork of the cyclic pivot. Remove stainless steel hole plug from rt. side of vertical firewall. Remove bolt holding the Al21-7 P-P tube rod ends to the aft fork of the cyclic pivot. IF FIREWALL PLUG NOT INSTALLED FOLLOW STEPS k &~D 1 (PLUG CAN BE INSTALLED FOLLOWING INSTRUCTIONS IN RHC KIT II KI-21). Disconnect both forward push-pull tubes from the swashplate and the forward push-pull tube from the jackshaft. Unscrew the three push-pull tubes from the rod ends attached to the aft end of the cyclic assembly. Disconnect 6-pin electrical connection at bottom of stick. Remove cyclic assembly from rotorcraft, Installation of Cyclic Assembl I WARNING I Rigging must be checked if the following has occurred: 1. Replacement of the cyclic assy. 2. Replacement of the A338-l cyclic oox or A320-l cyclic stick. 3. Replacement or change of A205-l Yoke (between collective and cyclic). 4. If the rod ends have been removed from the push-pull tube or push-pull tube length was changed on the Al21-l,-3,-5 or -7 push-pull tubes. 5. Jackshaft support length is changed. Page 8.4 Issued 5/22/87

9 MOCELR Installation of Cyclic Assembly (cont'd) On cyclic installation ensure right trim end cap fits flus h into left keel panel hole. Ensure cyclic friction stackup is not misaligned and the friction is on, to hold stackup in place. a) Install cyclic assembly. Attach cyclic box to keel panels. Ensure friction assembly clears all wires on installation. b) Attach cyclic friction assembly to cabin. Torque NAS1030 attach bolts to 40 in-lbs. plus locking torque. IF P-P TUBE ROD ENDS DISCONNECTED FROM FO~~ USING PLUGGED HOLE IN FIRE\.JALL, FOLLmv STEP c) AND d). c) Attach the Al21-7 P-P tubes to the fork of the cyclic pivot. Install the AllS-1 spacers outboard of the rod ends and the long spacer in between, torque nut and install palnut. d) Move cyclic stick full fwd and connect Al21-3 P-P tube to the cyclic stick fork bellcrank. Spacers to be installed on each side of rod end, lockwasher under the nut and torque. I WARNING I Smaller diameter of the AllS-1 spacer must be against the rod end ball. IF FIREWALL PLUG NOT INSTALLED, FOLLOW STEPS e) and f) e) Screw the Al21-3 P-P tube onto the aft rod end of the Al75 bellcrank assembly. (See Figure 8-3) f) Screw the two Al21-7 P-P tubes onto the two aft rod ends attached to the cyclic fork. No palnut required on rod end of A205 fork g) If A205-l fork was removed from forward rod end of Al75 bellcrank, screw the fork onto the rod end to 3.45 inches from center of rod end hole to center of attaching bolt hole. (See Figure 8-3) h) Install collective stick (standard or removable) (See Section 8.212). i) Attach the A205-l yoke connecting the cyclic stick assembly and the collective stick assembly. (See Section 8.212) j) Connect Al21-3 P-P tube to the jackshaft. (See Section 8.312) k) Connect both Al21-7 P-P tubes to the swashplate. (See Section 8.412). Issued 5/22/87 Page 8.5

10 MOOELR22 CYCLIC CONTROL STICK Al21-5 P/P TUBE LEVEL TO M.R.HUB COLLECTIVE CONTROL STICK A337-l JACK SHAFT A333-l COLLECTIVE STOP ~ ~ = -=----:= ~======~---- A211-l CYC. CONTROL STOP PLATE, Al21-l P/P TUBE FIGURE 8-3 CYCLIC AND COLLECTIVE CONTROL Al21-7 P/P TUBE A175-1 BELLCRANK (STANDARD & HP) OR A958-1 BELLCRANK (ALPHA, BETA, & MARINER) Page 8.6 Issued 5/22/87

11 MOCELR Installation of Cyclic Assembly (cont'd) j) Install cyclic box cover. 1. Connect post lightwire and ty-rap clear of controls, 2. Insert right trim shaft through cover and install knob. 3. Attach power plant controls to the cyclic box cover. 4. Install cyclic box cover and tighten the attaching screws. k) Install cyclic friction knob. See Section for adjusting cyclic friction assembly. 1) Move flight controls throughout complete travel. Verify no binding or clearance problems. m) Rig flight controls per Section I WARNING I Ensure all jarnnuts and attaching hardware has been torqued per Section Fastener Torques. n) Install all seat backs and inspection covers Cyclic Grip Assembly (Standard or Removal) Removal of Cyclic Grip Assembly. This may be accomplished, if necessary, without removal of complete cyclic assembly from rotorcraft. a) Remove bottom center inspection panel. Disconnect 6-pin connector and use pin extractor to remove the pins from the connector. Issued 5/22/87 Page 8.7

12 MODEL R Removal of Cyclic Grip Assembly (cont'd) b) Remove end cap from the cyclic grip pivot. c) Remove cotter pin, nut and Al41-14 washer. d) Gently tap cyclic grip shaft (DO NOT damage threads) and remove cyclic grip assembly from A320-l stick. DO NOT damage bearings in removal. The six wires are grouped into two sets of three wires each on the bottom right side of the cyclic stick with heat shrink around all six to prevent chafing. e) Remove the heat shrink and attach two pieces of 0.032" or 0.020" safety wire. One piece of safety wire on one of the wires in each group. Pull each wire group out of the stick, but leave the two pieces of safety wire protruding from each end Installation of Cyclic Grip Assembly (Standard or Removable ) a) Cyclic grip assembly may be installed without removal of complete cyclic box assembly from rotorcraft. Mark wire numbers near pins for later re-installation. 1. Remove bottom center belly panel. 2. Remove pins from connector. Rigging check not required after cyclic grip installation. b) Ensure rollpin is installed in the grip assembly. Heat shrink and two grommets should already be installed over the six wires coming out of the grip assembly. Page 8.8 Issued 5/22/87

13 MOOEL R Installation of Cyclic Grip Assembly (cont'd) The six wires are to be grouped into two sets of three wires each. One group will extend through the forward right side of the cyclic stick and the other will extend through the aft right side. c) Using two pieces of safety wire extending from the top aft electrical hole in the cyclic, one through the bottom right forward side of the stick and the other through the bottom right aft side, stagger and tape three wires onto each safety wire. Carefully pull the safety wire and wires through the cyclic stick. d) Attach heat shrink around all six wires and slide shrink tubing into stick as far as possible to prevent chafing. e) Reinstall pins on each wire into proper position connector. Housing Pin Location l Standard Cyclic Wires Removable Cyclic Wires f) Reconnect the cyclic wiring connector. g) Slide grip assembly into bearings in stick assembly. Install Al41-14 washer and castellated nut. I CAUTION I Secure nut until there is no axial movement of bearings and cylic grip assembly. DO NOT overtighten assembly as it will damage the bearings. h) Install cotter pin and end cap. i) Install bottom rotorcraft inspection panels. Issued 5/22/87 Page 8.9

14 MOCEL R Cyclic Lateral (Right) Trim The function of the cyclic lateral trim spring is to remove the left stick force in cruise conditions. It is actuated by pulling up on the black knob located forward of the cyclic stick. The trim spring (two sizes available) may be changed or shimmed to create the force necessary to balance the cyclic control laterally. This usually is required after a main rotor blade change. Use the following procedures to remove, change, shim and replace the trim spring assembly: Right Trim Spring Assembly Removal a) Remove right trim knob. b) Remove cyclic friction knob. c) On the in-flight adjustable lateral trim assemblies, remove the lateral trim adjustment knob located on the left side of the console. d) Remove four (4) attaching screws holding the powerplant control cables (mixture and carb heat). e) Remove cyclic box cover attaching screws. f) Disconnect cyclic box cover post light at disconnect. g) Disconnect right trim assembly attach bolt. h) Firmly grasp the spring assembly, tip the cyclic stick to the right to relieve some of the spring pressure. Pull up and to the right to remove the assembly Right Trim Spring Assembly Installation a) Move the cyclic stick to the right to relieve some of the spring tension for installation. Firmly grasp the spring assembly and insert the right trim spring cap flush into the left keel panel while ins~alling the spring assembly. Pivot into the cyclic stick pivot forks. b) Install bolt to connect assembly. Torque attaching nut to 100 in.-lbs plus nut drag. c) Connect cyclic cover post light wire and ty-rap clear of moving controls. d) Install cyclic box cover to airframe. Tighten all attaching screws. Page 8.10 Issued 5/22/87

15 MODEL R Right Trim Spring Assembly Installation (cont'd) e) Tighten four attaching screws holding the powerplant control cables (mixture & carb heat). f) Install right trim knob. g) Install cyclic friction knob. Install rollpin and safety wire. h) On the in-flight adjustable lateral trim assemblies, install the adjustment knob on the trim assembly shaft located on the left side of the console Right Trim Spring Replacement & Shimming (See Fig. 8-4) a) Spring Replacement 1. Remove the right trim assembly per Section Remove the cotter pin from the clevis pin. 3. Squeeze the spring and remove the clevis pin. 4. Remove the A581-l arm, A588-l spacer, and A583-1 spring cap. 5. Replace the spring as indicated by flight testing. Changing of the trim spring will create a large change in trim. Shimming of the springs may be required to obtain the desired trim forces. On the in-flight adjustable lateral trim assemblies, remove the A584-l bearing support and Al30-46 spacer. Remove the A583-2 cap by unscrewing it from the assembly shaft. 6. Reinstall the A581-l spring cap, A588-l spacer, and A583-l arm. 7. Install the clevis pin and cotter pin. On the in-flight adjustable lateral trim assemblies, install the A583-2 cap on the shaft, then the Al30-46 spacer, then the A584-l bearing support. 8. Install the right trim assembly per Section Issued 5/22/87 Page 8.11

16 MODEL R22 NUMBER PART NUMBER DESCRIPTION Knob 2 A587-1 Stem 3 A589-1 Guide 4 A586-1 Fork 5 MS Cotter Pin 6 MS Cl3 Pin 7 AN960-4 Washer 8 A585-1 Shaft 9 A581-1 Arm 10 A588-1 Spacer 11 A583-1 Cap 12 A618-1 or -2 Spring 13 AN or 416L Washers (As required for shimming) Retaining Ring (Circlip) 15 A104-3 Bearing 16 A584-1 Bearing Support 17 NAS Bolt 18 AN L Washers 19 A582-1 Plate 20 AN960-10L Washers 21 NAS679A3 Nut 22 A177-1 Pivot 23 NAS Bolt 24 NAS Nut 25 A587-2 Stem Roll Pin 27 A Shaft 28 ABYT4 Bearing 29 MS Cotter Pin 30 A586-2 Fork 31 NAS LE6 Screw 32 A583-2 Cap 33 B160-1 Pin 34 AN340-8 Nut 35 NAS Nut 36 A Spacer 37 Al30-45 Spacer 38 AN960PD10L Washer 39 A483-1 Knob Page 8.12 Issued 5/22/87

17 MODEL R22 11 r SHIM AT THIS LOCATION 12 8 \ 14 ~ - ) I J SHIM AT THIS LOCATION 11 1s I 16 FIGURE 8-4 RIGHT TRIM ASSEMBLY Issued 5/22/87 Page 8.13

18 MOCELR22 b) Shimming Right Trim Spring (See Fig. 8-4) 1. Remove the right trim assembly per Section Remove the trim spring per Section Slide the A583-l lower spring cap off the rod. I 4. Install shim washers between the A583-l lower spring cap and circlip as necessary to adjust trim force. On the in-flight adjustable lateral trim assemblies, remove A584-l bearing support, the A spacer, the A583-2 cap, the A618 spring and the A583-1 cap. Install shims between the A588-1 spacer and the A583-1 cap. When shimming the A618-1 (primer colored) spring (10.7 lb-in.) the maximum allowable shimming is (8) AN washers. When shimming the A618-2 (black colored) spring (14.5 lb-in.) the maximum allowable shimming is (5) AN washers. On the in-flight adjustable lateral trim assemblies, only the B056-l assembly with the primer (green) colored spring may be shimmed. The maximum number of shims is 3 AN washers. The B056-2 adjustable lateral trim assembly with the black colored spring must not be shimmed. I CAUTION I Shimming in excess of that indicated in the above S will cause the trim springs to bottom preventing full left cyclic travel. 5. Slide the A583-l lower spring cap, spring, A583-1 uppercap, A588-1 spacer, and A581-1 arm onto the rod. See Figure 8-4C. 6. Install the clevis pin and cotter pin. Page Reinstall the trim spring assembly per Section On the in-flight adjustable lateral trim assemblies, after the shims have been installed, reinstall the A583-1 cap, the A618 spring, the A583-2 cap, the Al30-46 spacer, and the A584-1 bearing support. Change 2: 4/15/88

19 MOCELR Selecting Longitudinal Elastic Trim Cord The Elastic Trim Cord is used to cancel out most longitudinal stick forces during cruise flight. If the cyclic grip moves forward in cruise flight, a weaker elastic trim cord is required. If the cyclic stick grip moves aft in cruise flight, a stronger elastic trim cord is required. a) Remove the elastic trim cord per Section and determine the strength of that cord; either by the I.D. tag attached or by the diameter of the cord and the length of cord from inner lock ring of one ena- to inner lock ring at the other end. The R22 parts catalog lists the elastic trim cords by part number and dash numbers also length, diameter and (force) load when installed. b) Following the statement above, and the amount of additional force required to keep the cyclic centered for level cruise flight, select an appropriate elastic trim cord. c) Install per Section d) Test fly helicopter to determine if proper cord was selected; repeat above procedure as required to find cord which will balance longitudinal cyclic stick forces. Issued 5/22/87 Page 8.15

20 MCCEL R22 This page intentionally left blank. Page 8.16 Issued 5/22/87

21 MOOELR22 FIGURE 8-4A SHORT ELASTIC TRIM CORD FIGURE 8-48 LONG ELASTIC TRIM CORD Issued 5/22/87 Page 8.17

22 MODELR22 FIGURE 8-4C CYCLIC RIGHT TRIM ADJUSTMENT WASHER FOR RIGHT TRIM ADJUSTMENT INSTALL AN OR AN L WASHER HERE WHEN INSTALLING LARGER (1.1 in.) BELLEVILLE WASHERS (4 ea.) THE SPACERS A AND A MUST BE SANDED TO THE LENGTH INDICATED. Al30-18 NEW LENGTH-.105/.115 in. A NEW LENGTH in. \ -Al30-19 SPACER Page 8.18 Change 11: 7 AUG 92

23 MCCELR Longitudinal Trim Cord Removal For inspection criteria of trim cord, See Section 2.410, Item 4. a) Remove the screws holdin3 the cabin bottom fore-aft inspection panel. If transponder antenna is installed on this inspection panel, slowly lower panel and disconnect the antenna lead and ground wire to the antenna, pull XPDR circuit breaker and tag C.B. with"antenna Rmvd." b) Push cyclic stick full forward. c) If short elastic trim cord installed as shown in Figure 8-4A, unhook trim cord at front tab of Al21-l push-pull tube and at clip mounted to support to remove trim cord. d) To remove long elastic trim cord installed as shown in Figure 8-4B, disconnect bottom hook and relieve tension on cord to remove the top hook connected to front tab of Al21-l push-pull tube Longitudinal Trim Cord Installation a) Ensure clamp and clip are installed per Figure 8.4A b) For short cord installation see Figure 8-4A c) For long cord installation see Figure 8-4B d) Check clearances of trim cord hooks to push-pull tube~ wire bundle and comm. wires out of bottom of cyclic stick. I WARNING I Ensure clearance is maintained between the trim cord hooks and the push-pull tubes and wiring throughout entire cyclic control travel. e) Connect XPDR antenna lead and ground wire if installed on inspection panel. f) Install panel and tighten attachment screws. g) Remove tag and engage circuit breaker. Change 7: 12 JAN 90 Page 8.19

24 MODELR Cyclic Friction Assembly Cyclic Friction is located in the front left corner of the cyclic box cover. Turning the knob clockwise applies friction to both the longitudinal and lateral cyclic. If friction cannot be applied by turning knob clockwise, adjustment of friction may be required Cyclic Friction Adjustment a) Turn friction knob counter-clockwise until it stops. b) Remove the roll pin. c) Lift knob off shaft. d) Install a thick or thin washer (AN or 416L) as required to give the proper friction at the center of the cyclic grip measured in a lateral direction. See Figure 8-4C. System friction with right trim off, fore and aft trim cord removed, and CYCLIC FRICTION OFF: 0-5 lb. - Lateral 0-7 lb. - Fore and Aft CYCLIC FRICTION ON: 7-13 lb. - Lateral e) Replace knob and install roll pin. f) Move flight controls throughout complete travel. Verify no binding or clearance problems. If friction assembly will not tighten install larger (1.1 inch) belleville washers (4 ea.) Bll and change length of spacers per Figure 8-4D. I CAUTION I New friction knob which has roll pin hole drilled thru knurled section of knob must be used with (1.1 inch) belleville washers. Page 8.20 Change 7: 12 JAN 90

25 MOCEL R Al21-7 Push Pull (P-P) Tube Al21-7 Push-Pull Tube Removal a) Remove belly panel, vertical panel between seat backs and mast fairing, disconnecting pitot line at pitot fitting. b) Remove vertical firewall maintenance hole plug to remove Al21-7 P-P tubes. IF HOLES NOT PRESENT, INSTALL USING RHC KIT KI-21. c) Remove NAS bolt attaching -7 P-P tube rod ends to cyclic fork. d) Disconnect bolts holding Al21-7 P-P tubes at swashplate. e) Tape sheet metal edges to prevent P-P tube removal damage. f) Position swashplate and rotor to slide Al21-7 P-P tube up and clear. Mark right and left tubes if they are to be reinstalled. g) Inspect P-P tubes and sleeves for damage. h) Inspect P-P tube guide for wear. The guide should be replaced if excessively worn or if fretting evident between guide material and riveted aluminum support. If P-P tube replaced, adjust rod ends to obtain same center-to-center length or M.R. Flight Controls will require rigging per R22 Maintenance Manual Section Al21-7 Push-Pull Tube Inspection/Repair 1. Nicks, cuts or scratches in the tube which are longitudinal not more than inches deep, or across the tube and not more than inches deep may be polished out. 2. Dented or flattened tube of more than five percent of its diameter must be replaced. 3. Maximum tube wear at guide inch per wall after smoothing wear ridges. Epoxy primer repair surfaces before sleeve installation. Any tube wear requires sleeve installation. 4. Replace tube worn in excess of inch after polishing. Issued 5/22/87 Page 8.21

26 MODEL R Sleeve Installation Onto Al21-7 Push-Pull Tube Repair any wear damage on Al21-7 P-P tube per Section prior to the P-P tube sleeve installation. a) Clean P-P tube by lightly using MEK or acetone. b) Apply tape to restrict adhesive to 6.5 inch area located 31 inches from end of P-P tube (not end of rod end). c) Test paint for paint bubbling; apply l-inch band of adhesive to one end of 6.5 inch area. If paint bubbles, remove paint and apply epoxy primer to area before applying adhesive to whole 6.5 inch area. I WARNING I Adhesive to be applied to complete area under P-.P tube sleeve. d) Apply adhesive supplied in kit to whole 6.5 inch area. (It will set and become stringy very quickly. Brush thin coat of adhesive without large lumps as rapidly as possible). Sleeve must be installed within two minutes after adhesive applied. e) Slide sleeve onto tube and center of adhesive. f) Rotate tube and apply heat using up to 1200-watt heat gun to evenly shrink sleeve producing smooth surface. I CAUTION I DO NOT APPLY HEAT CONTINUOUSLY TO SAME AREA. g) Allow to cool and apply adhesive to seal end of sleeve. Do not have adhesive at ends above surface of sleeve or sleeve will be damaged or will not enter guide during installation Push-Pull Tube Sleeve Inspection a) Visually inspect sl,eeve for wrinkles, pin holes. bubbles, gouges, torn areas. etc. Replace sleeve if any damaged or suspect areas are found. Page 8.22 Issued 5/22/87

27 MCCEL R Al21-7 Push-Pull Tube Installation a) Inspect P-P tube guide for wear. The guide should be replaced if excessively worn or if fretting evident between guide material and moveable guide plate. Old-style guide bushings which are riveted to fuselage must be replaced with moveable guide kit (RHC Kit KI-19A) if Al21-7 Push-Pull tubes are worn. Reference RHC Service Bulletin :fj36. b) Loosely (snug) install moveable guide on underside of airframe support A439-l per Figure 8-4E. I CAUTION I Extreme care must be taken when installing Al21-7 P-P tube into guide to prevent damage to P-P tube sleeve. c) Install Al21-7 P-P tube, ensure spacers installed properly. Reference Figure 8.4E.Torque attach bolt 100 in.-lb. plus nut drag. d) Attach Al21-7 P-P tubes to swashplate. Torque attach bolts 100 in.-lb. plus nut drag. e) Raise collective approximately seven (7) inches (measured from pilot throttle handle to center panel) with cyclic neutral. f) Tighten guides three attach bolts to slight friction and verify Al21-7 P-P tubes are centered in guide bore. Torque guide attach bolts 40 in.-lb. and torque stripe nuts. g) Remove protective tape from sheet metal edges used to protect P-P tubes during installation. h) Check full travel clearances of flight controls. 1) Upper frame forward two boltheads at horizontal firewall to Al21-7 P-P tubes minimum clearance.010 inch. 2) Fuel tank top inboard flange to left Al21-7 P-P tube minimum clearance.10 inch. Issued 5/22/87 Page 8.23

28 MOCELR Al21-7 Push-Pull Tube Installation (cont'd) i) Verify fasteners disconnected are retorqued per R22 Maintenance Manual Section j) Reinstall panels, fairings and firewall plugs. k) If rod ends were unscrewed from P-P tubes, main rotor rigging must be re-checked per Section 10. "V" Bulkhead Fwd. FIGURE 8-4E PUSH-PULL TUBES AND GUIDE Page 8.24 Issued 5/22/87

29 MOCELR COLLECTIVE CONTROL Collective Stick Assembly (Standard or Removable) Collective Stick Removal a) Remove vertical center panel, right and left seat backs and collective boot. b) Remove collective spring guard in aft left baggage compartment. c) Place collective in full down position. Use either the MT294-1 collective spring tool or Q.032"safety wire to remove the spring assembly. If safety wire is used, twist wire around rod end to rod end several times to assure that the spring assembly can be removed safely. I WARNING I Spring is under compression and failure to comply with above procedure can cause bodily harm and/ or damage to rotorcraft. d) Remove bottom spring attach bolt slowly while moving collective slightly to put spring tension onto res training safety wire. When belt is removed, swing the spring assembly forward for more clearance during removal. e) Disconnect collective stop at the A348-l seat belt anchor. Issued 5/22/87 Page 8.25

30 MOCELR Collective Stick Removal (cont'd) To prevent damage, rotate collective stop slider in line with collective handle and tape in place. I f. Disconnect A205 yoke from collective stick. g. Disconnect A327-1 overtravel spring from collective throttle arm. If installed, disconnect aft end of carb heat assist push-pull tube from collective stick. i. Disconnect two NAS attach bolts at either end of collective stick. j. Remove collective stick assembly Collective Stick Installation a. Assemble A332-1 friction lever per Figure 8-5. The spring washers, item 14, should be assembled with their concave sides together. The two washers, item 13, are installed with the grey Teflon -coated surface against the A333-1 stop (item 12). The A332-1 lever is threaded onto the NAS P screw as the screw starts to protrude from the attachment fitting. See collective friction adjustment for finalizing friction assembly after completion of collective installation. Refer to Section b. (Reference if not installed). Install A205-1 fork to the forward rod end of the A bellcrank on the cyclic fork. Dimension of A205-1 fork should be 3.45 inches from center of rod end hole to center of attaching bolt hole. No palnut required on this rod end. If new A bearings installed, ream to I inch inner diameter with dead sharp reamer (see Section 8.600). Page 8.26 Change 22: MAR 2004

31 MOCELR22 I 8 19~ 18 FIGURE 8-5 COLLECTIVE FRICTION ASSEMBLY NUMBER PART NUMBER DESCRIPTION NUMBER PART NUMBER DESCRIPTION 1 AN R6 Screw 13 Al41-20 Washer 2 A332-1 Lever S Belleville Washer 3 A431-l Knob 15 NAS P Screw 4 AN960-8L vjasher 16 AN Hasher (A/R) 5 NAS Nut 17 AN L t~asher (A/R) 6 NAS Screw 18 AN960-10L vja sher 7 A959-1 End Cap 19 NAS Bolt 8 A348-1 Anchor 20 NAS679A3 Nut 9 A601-l Grab-On Grip 21 MS Pal nut 10 A757 or A758 Collective Assy 11 A130-4 Spacer 12 A333-1 Stop Change 15: 26 JUL 96 Page 8.27

32 MODELR22 10 FIGURE 8-6 UPPER OVERTRAVEL SPRING INSTALLATION NUMBER PART NUMBER DESCRIPTION 1 A341-1 Spacer 2 C342-1 Arm Assembly 3 A Washer 4 A335-1 Torque Tube Roll Pin 6 AN 960-lOL Washer 7 NAS 679A3 Nut 8 MS Pal nut 9 A486-1 Screw 10 A327-1 Overtravel Spring Assembly 11 MS20995C in. dia Safety Wire Page 8.28 Change 22: MAR 2004

33 MOCELR Collective Stick Installation (cont'd) c) Install collective stick into rotorcraft. d) Connect collective inboard and outboard attach bolts. Special All5-l spacer required against the A329-l bearing block assembly. Smaller end against inner ball; larger end against bolthead. Torque to 100 in~bs. plus nut drag. Install palriuts. Attach A205-l fork to the collective stick. Torque to 100 in-lb. plus nut drag. Install palnut. Verify smooth operation of fork pivot. e) Install lower end of A333-l stop to the A348-l seat belt anchor. When installing A333-l stop onto the Al30-4 spacer, add AN and 416L washers on either side of stop as required to prevent binding and to obtain zero to.031 inch axial play. Torque nut to 27 in.-lb. plus nut drag. Install palnut. Check for binding and axial play. f) Connect collective spring and install cover per Section 8. I WARNING I Failure to remove restraining safety wire after collective spring is installed can limit control travel creating a safety-of-fligh.t hazard. g) Install the A327-l overtravel spring to the end hole of the A342-l collective arm. (See Fig. 8-6). Use special A486-l screw and A341-l spacer. With screw head against rod end, install spacer with large diameter against collective arm. Torque to 28 in.-lb. plus nut drag. Install palnut. Issued 5/22/87 Page 8.29

34 MOOELR Collective Stick Installation (cont'd) WARNING Improper installation can cause binding, rod end damage or rod end separation with subsequent loss of engine throttle control If installed, connect aft end of carb heat assist push-pull tube to flat side of collective arm. i. Adjust throttle correlation rigging per Section j. Install panels and seat backs Collective Spring Assembly (See Figure 8-8) The collective spring assembly is installed to balance in-flight main rotor collective control forces. A038-1 thru -7 spring assemblies may be adjusted or springs changed to rebalance collective control using the following springs and procedure: Assembly P /N Spring P/N Spring Color Spring Constant A038-1 A429-1 (old) Silver 89 lb/in. A038-2 A429-2 (old) Primer 35 lb/in. A038-3 or -5 A429-3 Grey 50 lb/in. (weak) A038-4 A429-4 (old) Black 70 lb/in. A038-6 A429-5 Gold 50 lb/in. (standard) A038-7 A429-8 White 71 lb!in. (strongest) Adjust A038-1, -2, -3, and -4 spring assemblies per Section Adjust A038-5, - 6 and -7 spring assemblies per Section A038-5 spring assembly replaces A038-2 assembly. A038-6 assembly replaces A038-1, -3, & -4 assemblies. WARNING Exercise extreme care when working with compressed collective springs. Always relieve spring compression slowly Collective Spring Removal a. Remove left seat back. Remove fuel valve handle. Page 8.30 Change 22: MAR 2004

35 MODELR22 UP h-.---.l.a: " STAINLESS STEEL SAFETY WIRE 4.30/4.00" 1 ~ \ A038-1 through -4 COLLECTIVE SPRING ::'@'(@ ASSEMBLY 3~~ 7 ~l0s \ 8~~\\ 4 /r ~~6 9"" -~~\ 5 y I A038-5, -6, &-7 COLLECTIVE SPRING ASSEMBLY 2/;@_~~3 4 3 /u~ 14 I 5 r-r-:5'"6 1r"15 '~~ ---,0 MT294-1 COLLECTIVE SPRING TOOL INSTALLED FIGURE 8-7 A038-1 THROUGH -4 COLLECTIVE SPRING ASSEMBLY '~ 7 4 ft!n~ \ 1\J' 1 ; '-._\ ~ ---~~'-- FIGURE 8-8 COLLECTIVE SPRING ASSEMBLY NUMBER PART NUMBER Change 16: 19 SEP 97 DESCRIPTION A Rod End NAS679A3 Nut AN960-10L Washer NAS Bolt NAS679A06 Nut AN960-6 Washer AN315-3R Nut A426-3 Plate MS Cotter Pin NUI~BER PART NUMBER DESCRIPTION A428-1 Rod A429-l thru -4 Spring A426-4 Plate AN Washer B292-3 Rod End A426-5 Cap A429-3, -5, or -8 Spring A426-6 Cap MS Pal nut Page 8.31

36 MOCELR Collective Spring Removal (cont'd) attach screws and fuel valve plate. b) Remove REMOVE ener. clip. move. the collective spring cover. Loosen - DO NOT screw located on aft vertical firewall stiff Remove screw at top of cover from nut or nut Slide cover from under loosened screw and rec) Place the collective in the full down position. Use either the MT294-1 collective spring tool or.032 in. safety wire to remove the spring assembly. If safety wire is used, twist wire around rod end to rod end several times to assure that the spring assembly can be removed safely. I WARNING I Spring is under compression and failure to comply with procedures can cause bodily harm and/or damage to rotorcraft. d) Remove bottom spring attach bolt slowly while moving collective slightly to put spring tension onto restraining wire. e) Disconnect upper spring assembly attach bolt and remove the spring assembly Collective Spring Installation Overall compressed length for installation to be 4.30/4.00 in. between centers of the roq ends. The nut end of the rod guides to be pointing up (See Figure 8-7). I WARNING I When installing the A038-5 or -6 spring assembly, both rod ends must be bottomed (B292-3 rod end has left-hand thread). Failure to bottom both rod ends can cause either one to run out of threads during adjustment and can cause bodily harm. a) Insert collective spring assembly into the collective stick attachment arm. Install bolt and torque to 40 in.-lbs. plus nut drag. b) Move collective to align rod end into lower mount. Install bolt and torque to 40 in.-lbs. plus nutplate locking drag. Page 8.32 Change 9: 5 JUL 90

37 8.222 Collective Spring Installation (continued) c) On installation of the spring assembly, be sure to cut and remove the restraining safety wire. d) Check to make sure that the spring coils are not binding with collective stick full down. Adjust spring assembly as required per or Install collective cover. WARNING Failure to remove the safety wire or allowing the spring coils to bind can limit the control travel creating a safety-of-flight hazard. e) Install co-pilot seatback. Tighten seatback screws. Tighten four (4) fuel valve plate attach screws. WARNING Ensure proper fuel valve handle orientation. f) Install fuel valve handle. Verify proper orientation using gascolator drain. (See Fuel Flow Check ) Collective Spring Adjustment for A038-1 thru -4 Assembly a) Small force adjustments may be made by screwing the lower rod end in or out. Install the MT294-1 collective spring tool. Remove the lower bolt and loosen the adjustment. After reinstallation, ensure that the spring coils do not bottom out with the collective full down. The maximum extension for the bottom rod end is 1.1 inches provided the spring coils do not bottom (See Figure 8-7). b) Remove the collective spring per c) Place spring assembly in a soft-jawed vise. d) Compress the spring slightly and cut the safety wire. e) Carefully open the vise to relieve the spring tension and remove the spring. f) Install a spring selected from the table in to obtain the desired trim force. g) Compress the spring assembly in a vise to a dimension of 4.30/4.00 inch between the rod end center lines. Safety wire with inch diameter stainless steel safety wire (see Figure 8-7). h) Reinstall the collective spring assembly per OCT 2018 Chapter 8 Flight Controls Page 8.33

38 8.224 Collective Spring Adjustment for A038-5, -6, or -7 Assembly Large spring force adjustments are made by changing spring. Small spring force adjustments may be made as follows: a. Remove collective spring cover. b. Loosen palnut and jamnut on lower rod end. c. With collective up, rotate spring by hand to increase or decrease spring force (lower rod end is right-hand thread; upper rod end is left-hand thread). Screwing rod end in decreases collective-up force. Extending rod ends increases collectiveup force. WARNING Ensure that spring coils are not binding with collective stick full down after making adjustment. Binding spring coils can limit flight control travel. d. Standard torque jamnut and palnut per e. Install collective spring cover Collective Friction Adjustment (see Figure 8-5) To adjust collective friction: a. Loosen nut (item 5) on friction lever and position lever in locked position. b. Turn screw (item 15) in threaded collective attachment fitting clockwise to increase friction, counter-clockwise to decrease friction. c. Adjust locked friction to 12 to 20 pounds measured at collective grip, using a spring scale pulling up from bottom of travel. WARNING Collective friction greater than 20 pounds may prevent aircraft from entering autorotation. d. Tighten nut (item 5) on friction lever. Page 8.34 Chapter 8 Flight Controls OCT 2018

39 MOCELR RPM Governor System The governor system senses engine RPM and applies corrective input forces to the throttle; when RPM is low, governor increases throttle and vice versa. Throttle inputs are through a friction clutch which can be easily overridden by the pilot. The governor is active from 80% - 115% engine RPM and can be switched on or off by the pilot using the toggle switch on the end of the right seat collective control. The governor system is designed to assist the pilot in controlling the RPM in the normal operating range. It may not prevent over- or under-speed conditions generated by aggressive flight maneuvers. Within the active range there is a 3%-wide deadband from 102.5% % where the governor will not take action provided the rpm is steady. The governor system consists of the following major components: 1. The governor controller, a solid-state analog-circuit control unit mounted behind the left seat back. The controller senses engine RPM via tachometer points in the engine right magneto (helicopter left side) and provides a corrective signal to the governor assembly. 2. The governor assembly, attached to the collective stick assembly behind the left seat back. When activated by the governor controller, the governor gearmotor and attached worm gear drives a friction clutch connected to the throttle Governor Controller Removal 1. Remove left seat back assembly to gain access to controller. WARNING No external adjustment of controller is available. If controller fails to operate correctly, remove and return it to RHC. 2. Disconnect electrical connector. 3. Remove four screws securing governor controller to left seat back assembly Governor Controller Installation 1. Secure governor controller to left seat back assembly. 2. Connect electrical connector. 3. Install seatback panel. If fuel valve handle has a hexagonal mating recess, perform fuel flow check per Section Governor Assembly Removal The governor assembly is behind the left seat back assembly, attached to the collective stick. 1. Remove collective stick per Section Change 22: MAR 2004 Page 8.34A

40 -577 WIRE ROBINSON --,t= MAINTENANCE MANUAL t ROUTE -576 AND -577 WIRES WITH EXISTING MAIN WIRING HARNESS USING MS OR MS TV-RAPS. GOVERNOR y<=9l )I ON-OFF SWITCH : j - -- LEFT KEEL PANEL B297-2 CIRCUIT BREAKER -576 WIRE WITH B260-2 TERMINAL ~ w-~,._.-a o-o-ec_a_l L \..: ; ( ~tt:~; I I SJ:r~,: I.. 1 l o- ~' N! g WIRES TO MICRO SWITCH AND POSITION LIGHT MODELR22 -- / / " '\ I I \ -+--t- 1 I / \ ~ B804-2 HARNESS ASSEMBLY 1 1 ~S3116Fl2-10SX PLUG TO B286-2 CONTROLLER \ _;i...:..;,..;,..:_ COLLECTIVE STICK-ACTIVATED MICRO SWITCH,! ~- FIGURE 8-8A \S:7 LEFT POSITION LIGHT (VIEW LOOKING DOWN) FIGURE 8-8B RPM GOVERNOR INSTALLATION GOVERNOR ASSEMBLY Page Change 15: 26 JUL 96

41 R 0 BIN SON MAINTENANCE MANUAL MOCELR Governor Assembly Removal (cont'd) 2. Remove three screws securing governor assembly to collective stick. 3. Remove bolt securing governor assembly's output arm to link assembly. WARNING No adjustment of friction clutch is permitted. No field replacement of gearmotor is permitted. If friction setting is incorrect, or if gearmotor operates incorrectly, remove governor assembly and return to RHC Governor Assembly Installation 1. Connect governor assembly's output arm to link assembly. Ensure: a. NAS bolt head toward collective grips and no washer under bolt head. b. AN or NAS washer between governor output arm and rod I end. c. AN960-1 OL washer between rod end and nut. Torque nut and palnut per Section Link assembly length must be inches rod end centerto-center. 2. Ensure governor assembly's output arm points upward towards collective's throttle connecting rod. Attach governor assembly to collective stick. Torque NAS P screw per Section Torque both AN screws to 27 in.-lb and safety wire with inch diameter safety wire. 3. Rotate throttle grips. Verify smooth operation and no interference. 4. Install collective stick per Section Governor Troubleshooting The majority of governor problems are caused by the engine's right (helicopter left side) magneto tachometer contact assembly (points) being out of adjustment or faulty. Refer to TCM Master Service Manual for tachometer contact assembly installation and adjustment. When operating in the 80%-115% active range, the R22 governor will attempt to maintain engine rpm at 104%±1.5% (102.5%-105.5%). The edges of this governed 3%-rpm wide window, called a "deadband", may be detected as follows: 1. Start engine and run-up helicopter per Pilot's Operating Handbook. Collective must remain fully down during this and following steps. Change 22: MAR 2004 Page 8.34C

42 MOCELR22,8.239 Governor Troubleshooting (cont'd) 2. Gently hold throttle and very slowly increase rpm (do not exceed 1 07%). Note and record engine rpm indication when governor input (subtle throttle resistance) is encountered. 3. Gently hold throttle and very slowly decrease rpm (do not go below 97%). Note and record engine rpm indication when governor input (subtle throttle resistance) is encountered. 4. Subtract Step 3 indication from Step 2 indication. approximately 3%. Result should be A result of 3% but centered beyond 1 04 ± 0. 5% is indicative of a governor controller problem. Results greater than 3% but still centered on 1 04% are usually indicative of excessive throttle linkage friction or insufficient governor friction. Check throttle friction by disconnecting overtravel spring assembly upper rod end from C342 arm and attaching a spring scale to the rod end. With carburetor throttle arm in idle position, slowly pull up overtravel spring assembly with spring scale and note maximum 4 pounds moving friction prior to full-open throttle at carburetor. Excessive throttle linkage friction can be caused by binding rod ends, control interference, carburetor throttle shaft bushing elongation, or binding carburetor accelerator pump (typically binds in one direction only). Check governor friction with collective down, collective friction on, overtravel spring assembly upper rod end disconnected from C342 arm, and C342 arm positioned horizontally. Attach a spring scale to hole in C342 arm and, with scale held tangential to arm, slowly pull on scale and note both the breakaway and the moving frictions. Breakaway friction is typically pound greater than moving friction. Breakaway friction 1 pound or greater than moving friction may indicate damaged or contaminated governor friction clutch. Moving friction must be minimum 8 pounds until arm stops moving. Insufficient moving friction can be caused by wear, contamination, or loss of spring rate. Proper governor operation requires a minimum 2:1 ratio of governor friction-tothrottle linkage friction. Erratic operation is usually indicative of tachometer contact assembly problems or wiring damage. Wiring damage may be evidenced by crushing, pinching, or abrasion, all of which can result in grounding of one or both center wire conductor(s) to the shielding or to structure. Tachometer contact assembly problems may be caused by contamination, oxidation, or loose contact(s), in addition to installation or assembly errors. Contamination can be caused by over-lubrication of cam follower felt, engine oil leaking past oil seal, or moisture intrusion thru vent plug. Oxidation can be caused by an obstructed vent plug or by engine oil leaking past the oil seal. When flying in turbulence, or if the engine is lightly "loaded" (drive train almost freewheeling), a fluctuating MAP indication is expected. Any loose connection in throttle linkage (including worn carburetor throttle shaft bushings) will result in both RPM & MAP oscillations. Page Change 22: MAR 2004